Ford 2.0 EcoBlue Engine

Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.
0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Specifications
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MATERIALS
NOTICE: These Parts urgently needed by engine removal and installation !

NECESSARY PARTS QUANTITY PART NUMBER
Lifting eye engine 1 GK2Q-17A084-AA
Bolt 2 W500624-S
ENGINE DATA - 105 PS
DESCRIPTION
Code YLFS
Emission level Stage 6
Firing order 1-3-4-2
Bore diameter 84.01 mm
Stroke 90.03 mm
Displacement 1996 cc
Compression ratio 16.5:1
Power output at 3500 rpm 77 kW (105 PS)
Torque between 1375 to 2000 rpm 360 Nm
Idle speed 850 rpm
ENGINE DATA — 130 PS
DESCRIPTION
Code YMFS

DESCRIPTION
Stroke 90.03 mm
Idle speed 850 rpm
DESCRIPTION
Code YNFS
Stroke 90.03 mm
Idle speed 850 rpm
DESCRIPTION
Code YLF6

DESCRIPTION
Stroke 90.03 mm
Idle speed 850 rpm
DESCRIPTION
Code YMF6
Stroke 90.03 mm
Idle speed 850 rpm
DESCRIPTION
Code YNF6
DESCRIPTION
Stroke 90.03 mm
Idle speed 850 rpm
ENGINE OIL CAPACITY WITH GREY DIPSTICK END
LITERS
Initial fill including oil filter 9.1
Oil Service fill without filter change 8.1
Oil service fill with filter change 8.3
ENGINE OIL CAPACITY WITH YELLOW DIPSTICK END
LITERS
Initial fill including oil filter 10
Oil Service fill without filter change 9.2
Oil service fill with filter change 9.8
CYLINDER BLOCK DIMENSIONS
DESCRIPTION MM
Cylinder bore diameter 84.000 - 84.020
Main bearing housing diameter 65.000 - 65.020

DESCRIPTION MM
Main bearing running clearance 0.035 - 0.065
PISTON DIMENSIONS
DESCRIPTION MM
Piston diameter 83.915 - 83.931
Squish hight 0.6045
Piston clearance in cylinder 0.069 - 0.105
Piston ring end gaps
— upper compression ring 0.250 - 0.400
— lower compression ring 0.850 - 1.100
— oil control ring 0.200 - 0.400
Piston ring gap position: The piston ring gaps must be distributed evenly around
the circumference of the piston. This also applies to the oil control ring elements.
Align the piston ring gaps at 120 degrees to each other.
CRANKSHAFT DIMENSIONS
DESCRIPTION MM
Crankpin diameter 49.970 - 49.990
Crankpin width 24.400 - 24.600
Main bearing journals 1 to 5 diameter 59.970 - 59.990
Main bearing shells 1,2,4,5 inner diameter — bearings installed 60.011 - 60.055
Main bearing shell 3 inner diameter — bearings installed 60.019 - 60.063
Main bearings 1,2,4,5 radial clearance 0.019 - 0.035
Main bearing 3 radial clearance 0.023 - 0.039
Crankshaft /Connecting rod running clearance 0.035 - 0.065
Upper main bearing max/min thickness 2.501 - 2.489

DESCRIPTION MM
Lower main bearing max/min thickness 2.501 - 2.489
Upper and lower main bearing liner free spread min 65.5
Thrust washer thickness 1.875 - 1.925
Crankshaft end float 0.090 - 0.305
CONNECTING ROD DIMENSIONS
DESCRIPTION MM
Connecting rod length 142.500
Connecting rod width 24.280 - 24.300
Connecting rod bearing shell inner diameter — bearings installed 46.971 - 47.015
Connecting rod bearing radial clearance 0.017 - 0.029
Connecting rod bearing axial clearance 0.100 - 0.320
Connecting rod big end bore diameter 53.000 - 53.013
Connecting rod small end bore diameter 30.012 - 30.020
PISTON PIN DIMENSIONS
DESCRIPTION MM
Piston pin length 63.350 - 63.650
Piston pin diameter 29.994 - 30.000
Piston pin slide clearance 0.011 - 1.860
Piston pin bore diameter 30.017 - 29.989
CAMSHAFT DIMENSIONS
DESCRIPTION MM
Camshaft end float - Axial play 0.025 - 0.060

VALVE DIMENSIONS
DESCRIPTION MM
Valve stem to valve guide clearance — intake valve 0.0255 - 0.0605
Valve stem to valve guide clearance — exhaust valve 0.0355 - 0.705
CYLINDER HEAD DIMENSIONS
DESCRIPTION MM
Maximum distortion — measured longitudinally and diagonally 0.100
Peak to valley height of mating surface 0.150
Thickness of cylinder head gasket with piston protrusion of 0.671 - 1.30 (one tooth)
0.720 mm Grade 1
Thickness of cylinder head gasket with piston protrusion of 0.721 - 1.35 (two teeth)
0.770 mm Grade 2
Thickness of cylinder head gasket with piston protrusion of 0.771 - 1.40 (three teeth)
0.820 mm Grade 3
Thickness of cylinder head gasket with piston protrusion of 0.821 - 1.45 (four teeth)
0.870 mm Grade 4
Thickness of cylinder head gasket with piston protrusion of 0.871 - 1.50 (five teeth)
0.920 mm Grade 5
OIL PRESSURE SPECIFICATIONS
DESCRIPTION PRESSURE BAR (KPA)
Minimum oil pressure at idle speed 1.0 (100)
Minimum oil pressure at 2000 rpm 1.5 (150)
LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES
ITEM SPECIFICATION
SAE 0W-30 Material: WSS-

M2C950-A (Engine
Oil - SAE 0W-30)
ITEM SPECIFICATION
Sealer — oil pan, crankshaft rearseal , ladderframe and engine front Material: WSE-
cover M4G323-A4
(Silicone Sealant)
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine - Component Location
Print
Description and Operation
Item Description
1 Oil cooler
2 Oil filter
3 Coolant pump
4 Intake manifold
5 Fuel rail
6 High pressure fuel pump
Item Description
1 Oil pan
2 Exhaust manifold
3 Thermostat
4 Vacuum pump
5 Valve cover
6 Turbocharger
Engine - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN)
- Engine - System Operation and
Component Description
Print
Description and Operation
System Operation
Intelligent Oil-Life Monitor (IOLM) and ‘variable’ oil change intervals
Ford vehicles are equipped with an Intelligent Oil-Life Monitor (IOLM) that determines when
the engine oil must be changed, based on how the vehicle is used. By considering several
important factors in its calculations, the IOLM helps to ensure that the engine performs at
its best while also helping to avoid unnecessary oil changes. The IOLM together with
advanced, high specification oils, allow greater distances to be achieved in between oil
changes, but this varies depending on how and where vehicles are driven.
Driving conditions and driving styles have an impact on the vehicle’s oil life. For example,
vehicles that are driven predominantly on highways will not experience the same level of oil
dilution as vehicles driven predominantly around town or in city centers, where frequent
engine starting and stationary periods are normal. Vehicles used as taxis, for multi-drop
deliveries, for short journeys, when stationary with the engine running for long periods of
time, will all experience greater levels of oil dilution than vehicles not operating under such
conditions.
Therefore, depending on driving style and conditions, some customers may not reach the
scheduled service interval before the engine oil life is depleted and requires changing. When
the oil life is fully depleted the following information message is displayed in the vehicle’s
instrument cluster: Oil Change Required. The driver is reminded with this message every
time the vehicle’s ignition is switched on. It is important that this message is not ignored
and the engine oil is changed as soon as possible to protect the engine from premature
wear and failure, no later than 1.500 km (1,000 mi) or one month, occurs first.
The following factors can reduce the interval between oil changes:
• Frequent low-speed city-center driving (below 50 kph/30 mph)
• Frequent short journeys (below 3 km/2 mi), where the engine does not reach its normal
operating temperature
• Frequent engine starting
• High engine load conditions, for example: driving the vehicle fully loaded, trailer towing,
frequent hill climbs.
To maximize the intervals between oil changes, the following conditions are recommended:
• The vehicle is not stationary with the engine running for long periods of time
• The vehicle is driven with engine speeds mainly above 1,700 rpm for at least 15 minutes
once the engine has reached normal operating temperature, at least once a week.
Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L
EcoBlue (96kW/130PS) (YM)/2.0L EcoBlue
(125kW/170PS) (YN) - Engine
Print
Diagnosis and Testing

Special Tool(s) / General Equipment
Compression Test Adapter
303-1651
Ford diagnostic equipment

Compression tester
Oil pressure gauge
UV leak detection lamp
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
VISUAL INSPECTION CHART
Mechanical Electrical
• Coolant leaks • Fuse(s)
• Oil leaks • Loose or corroded connector(s)
• Fuel system leaks • Damaged or worn switch(es)
• Visibly damaged or worn parts • Powertrain control module (PCM)
• Loose or missing nuts or bolts
3. If an obvious cause for an observed or reported concern is found, correct the cause (if
possible) before proceeding to the next step
4. If the cause is not visually evident, verify the symptom and refer to the Symptom
Chart.
Symptom Chart
Symptom Possible Sources Action

Loss of oil * Oil leaks from the engine or * CHECK for evidence of oil leaks
auxiliary components. on components. Use an ultraviolet
(UV) leak tester if oil leak is not
evident. INSTALL new gaskets or
components as required.
* Internal or external leak at the * CHECK the coolant expansion
oil cooler. tank for oil film on the coolant
surface. INSTALL a new oil cooler
or oil cooler gasket.
* Leak at the crankshaft front or * INSTALL a new crankshaft oil
rear oil seal. seal. REFER to: (303-01B Engine)
Crankshaft Front Seal
(Removal and Installation),
Crankshaft Rear Seal
(Removal and Installation).
Oil consumption * Use of the wrong type of engine * DETERMINE the last type of
oil. engine oil used (refer to the latest
invoice or oil receipt) and
compare with the specification.
INSTALL a new engine oil filter
and the correct engine oil.
REFER to: Specifications (303-
01A Engine, Specifications).
* Faulty positive crankcase * CHECK that the crankcase
ventilation system. ventilation system is operating
- Hoses or ventilation/breather correctly and repair as necessary.
valves are blocked. This causes
excessive pressure in the
crankcase which causes oil to
enter the combustion chamber.
- Crankcase ventilation oil
separator is faulty and engine
oil can enter the combustion
chamber through the intake
manifold.
* Turbocharger seals. * INSTALL a new turbocharger.
REFER to: Turbocharger (303-04C
Fuel Charging and Controls -
Turbocharger, Removal and
Installation).
* Damaged gaskets or mating * CHECK the gaskets and mating
surfaces. surfaces for damage.
- Cylinder head gasket is - REMOVE the cylinder head. Check
damaged or mating faces are the mating faces, cylinder head
warped. gaskets and the flatness of the
- Valve stem seals are worn cylinder head and engine block
causing engine oil to enter the mating faces.
combustion chamber between - INSTALL new valve stem seals.
the valve stem and the valve REFER to: Valve Stem Seals
stem guide. (303-01A Engine, Removal and
Installation).
* Piston ring or cylinder liner * INSTALL new components as
wear. necessary.
Coolant consumption * Cooling system components. *
REFER to: Engine Cooling (303-
03A Engine Cooling, Diagnosis
and Testing).
* Exhaust gas recirculation (EGR) * INSTALL a new EGR cooler.
cooler (if equipped). REFER to: Exhaust Gas
Recirculation (EGR) Cooler (303-
08A Engine Emission Control,
Removal and Installation).
* Oil cooler. * INSTALL a new oil cooler.
* Damaged gaskets or warped * REMOVE the cylinder head.
mating faces. REFER to: Cylinder Head -
Vehicles Built From: 01-11-2016
(303-01A Engine, Removal and
Installation).
CHECK the cylinder head gasket
for damage. CHECK the cylinder
head and cylinder block for
distortion.
* Cracks or fractures in engine * DETERMINE the damaged engine
components surrounded by component and INSTALL a new
coolant, such as cylinder liners component.
and cylinder head combustion
chamber.
Engine will not crank * Battery or cables. * CHECK the battery and cables.
REFER to: Charging System (414-
00 Charging System - General
Information, Diagnosis and
Testing).
* Starter motor or cables. * CHECK the starting system.
REFER to: Starting System (303-
06A Starting System, Diagnosis
and Testing).
Engine cranks but will * Fuel tank is empty. * CHECK the fluid level.
not start * Water in fuel. * DRAIN the water from the fuel
system.
REFER to: Diesel Filter Water
Drain-Off (310-00A Fuel System -
General Information, General
Procedures).
* Fuel filter blocked. * INSTALL a new fuel filter element.
REFER to: Fuel Filter Element
(310-01A Fuel Tank and Lines,
Removal and Installation).
* Air in fuel lines. * BLEED the fuel system. Check the
fuel system for leaks.
REFER to: Fuel System Bleeding
(310-00A Fuel System - General
Information, General Procedures).
* Engine intake air system. * CHECK the intake air system.
REFER to: Intake Air Distribution
and Filtering (303-12A Intake Air
Distribution and Filtering,
Diagnosis and Testing).
* Glow plug faulty. * CHECK the glow plugs.
REFER to: Glow Plug System
(303-07A Glow Plug System,
INSTALL new glow plugs as
necessary.
REFER to: Glow Plugs (303-07A
Glow Plug System, Removal and
Installation).
* Engine management system. * CHECK the engine management
system.
REFER to: Electronic Engine
Controls (303-14A Electronic
Engine Controls, Diagnosis and
Testing).
* Fuel pump faulty. * CHECK the fuel pump.
REFER to: Fuel Charging and
Controls (303-04A Fuel Charging
and Controls, Diagnosis and
Testing).
* Incorrect valve timing. * CHECK and adjust the valve
timing.
* Broken or damaged timing * CHECK the timing chain and
chain or sprocket. sprockets. INSTALL new
components as necessary.
Very poor power * Fuel system. * CHECK the fuel system
output/fuel components.
consumption too * Engine intake air system. * CHECK the intake air system.
high/engine running REFER to: Intake Air Distribution
rough and Filtering (303-12A Intake Air
Distribution and Filtering,
* Exhaust system blocked. * CHECK the exhaust system.
* Engine management system. *
CHECK the engine management
system.
REFER to: Electronic Engine
Controls (303-14A Electronic
Engine Controls, Diagnosis and
Testing).
* Turbocharger. * CHECK the turbocharger.
REFER to: Turbocharger (303-04C
Fuel Charging and Controls -
Turbocharger, Diagnosis and
Testing).
Testing).
* Incorrect valve timing, timing * CHECK and adjust the valve
chain or timing sprocket timing. INSTALL new components
damaged. as necessary.
Noisy running * Engine auxiliary components * CHECK engine auxiliary
loose or damaged. components for
damage/looseness.
Noisy running, * Incorrect fuel * DETERMINE which type of fuel
misfiring/backfiring was the last put in the tank (note
the country specific fuel
specifications).
* Water in fuel or fuel * CHECK the fuel system for water
contaminated. or other contamination.
REFER to: Diesel Filter Water
Drain-Off (310-00A Fuel System -
General Information, General
Procedures).
Testing).
* Valve timing incorrect, timing * CHECK and adjust valve timing.
chain or timing sprocket INSTALL new components as
damaged. necessary.
Noisy running/valve * Excessive valve clearance due * INSTALL new hydraulic valve
train noise to faulty hydraulic valve tappets.
tappets.
* Timing chain damaged. * INSTALL a new timing chain.
* Timing chain incorrectly * CHECK the timing chain tension.
tensioned. INSTALL a new tensioner, as
necessary.
* Timing chain guides worn or * CHECK the timing chain guides.
damaged. INSTALL new guides as
necessary.
Noisy running/engine * Engine components * CHECK the engine components
block - Pistons for wear or damage. Make sure
- Piston rings all components are within
- Connecting rod large end, main specification. INSTALL new
bearing or thrust bearing components as necessary.
journals
- Connecting rods bent or
damaged.
Engine Oil Leaks

NOTE: Before installing new gaskets or oil seals, make sure that the fault is clearly
established.
If the oil leak cannot be identified clearly by a visual inspection, carry out a UV test:
Ultraviolet (UV) Testing
1. Clean the engine and transmission with a suitable cleaning fluid such as brake
cleaner.
2. Pour test fluid GV-2911-3090A in accordance with the quantity specified by the
manufacturer through the oil filler neck into the engine and install the oil filler cap.
WARNING: On manual transmissions put the transmission into NEUTRAL. Failure to

follow these instructions may result in personal injury.
3. Start the engine and let it run for about five minutes.
4. Switch off the engine.
NOTE: If no leak can be found, road test the vehicle under various loads and again check
the engine for leaks.
5. Check the engine for oil leaks using a UV leak detection lamp GV-2929 or UV leak
detection lamp GV-2911 B11.
6. Rectify any leaks found and recheck the engine for oil leaks.
Measure the Compression Pressure
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always
present and can ignite. Failure to follow these instructions may result in personal injury.
NOTE: The powertrain control module (PCM) receives an error message when the relay is
removed or electrical components are disconnected. This error message must be deleted
from the fault memory by connecting the Ford diagnostic equipment after completing the
measurement.
NOTE: Valve clearance must be set correctly before performing a compression test. Make
sure engine is at the normal operating temperature.
NOTE: The varying design of compression checking devices and fluctuating starter motor
speeds normally only allows to check if the compression is even in all cylinders.
NOTE: The readings from the compression pressure check should be used as an indication
of cylinder balance. If one or more of the readings is significantly lower than the others,
investigate that particular cylinder for concerns.
1. Remove the glow plugs.

REFER to: Glow Plugs (303-07A Glow Plug System, Removal and Installation).
2. Install a suitable compression tester with Special Tool 303-1051 into the glow plug
bore.
NOTE: Crank the engine with the starter motor until the reading on the compression
tester stops rising.
3. Carry out the measurement on all cylinders, following the measuring equipment
manufacturer's instructions and compare each cylinder compression reading.
4. Detach the compression tester and adapter.
5.
Install the glow plugs.
REFER to: Glow Plugs (303-07A Glow Plug System, Removal and Installation).
6. Reset the PCM fault memory.
Measure the Oil Pressure

The oil pressure depends on various factors (engine speed, oil temperature, oil viscosity,
amount of oil filter contamination etc.).
NOTE: Measure the oil pressure at the specified engine speed. Measure the oil pressure at
an oil temperature of 80°C.
NOTE: The graphics used are for illustration purposes only.
1. Raise and support the vehicle.

REFER to: Jacking and Lifting (100-02 Jacking and Lifting, Description and
Operation).
2. Disconnect the oil pressure switch electrical connector.
3. Remove the oil pressure switch.

4. Attach the oil pressure gauge (GV 2134) with the oil pressure gauge connector.
5. Lower the vehicle.
6. Start the engine
7.
Raise and support the vehicle.
Operation).
NOTE: Oil pressure at 2000 rpm must be between 2.0 bar minimum and 5.0 bar
maximum.
NOTE: Oil pressure at idle must be 1.25 bar minimum.
8. Measure the oil pressure.
10. Stop the engine.
11.
Raise and support the vehicle.
Operation).
12. Remove the oil pressure gauge and the oil pressure gauge connector.
13. Install the oil pressure switch.
14. Connect the oil pressure switch electrical connector.
Valve Train Analysis - Static (Engine Off)
1. Remove the valve cover.
Check all components of the valve train for damage and wear. Make sure that only original
components are installed and that all nuts and bolts are tightened to the specified torque.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Camshaft and Carrier
Assembly
Print
Removal and Installation

Materials
Name Specification
Brake Cleaner -
Grease WSD-M1C227-A
Removal
1. Refer to: Timing Belt (303-01A Engine, Removal and Installation).

2.
3.
4.
5. NOTE: Use suitable paper to absorb any escaping fluid.

Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
6.
7.
8. NOTICE:
Extreme cleanliness must be exercised when handling the components.
Make sure that all openings are sealed with clean blanking caps.
NOTE: Use suitable paper to absorb any escaping fluid.
9.
10.
11.
12. NOTICE:
Make sure that all openings are sealed with clean blanking caps.
Procedures).
13.
14.
15.
16.
17. Refer to: Quick Release Coupling (310-00A Fuel System - General Information, General
Procedures).
18. NOTICE:
Make sure that the area around the component is clean and free of foreign
material.
NOTE: Discard the bolts.
NOTE: Note the position of the components before removal.
Discard the clamps.
19.
20. NOTE: Make sure that the component is at ambient air temperature.
Loosen each bolt 2 turns at a time until all bolts are removed.
21.
22. NOTE: This step is only necessary when installing a new component.
Torque: 10 Nm
Installation
1. NOTE: Make sure that the mating faces are clean and free of foreign material.
Material: - (Brake Cleaner)
2. NOTICE: Make sure that the component is correctly located on the locating
dowels.
NOTE: Make sure that a new component is installed.
dowels.
NOTE: Make sure that the component is at ambient air temperature.
NOTE: Only tighten the bolts finger tight at this stage.
Tighten each bolt 2 turns at a time.
Torque:
1-19: 5 Nm
4. Torque:
1-18: 10 Nm
19: 23 Nm
5. NOTICE: To avoid corrosion, lubricate the injector bodies prior to installation.

Material: WSD-M1C227-A (Grease)
6. NOTICE:
Take extra care when handling the components.

NOTE: Use new seals.
Refer to: Fuel Injection Component Cleaning (303-04A Fuel Charging and Controls,
General Procedures).
7. NOTE: Make sure that the components are installed to the position noted before
removal.
NOTE: Make sure that new bolts are installed.
Make sure that new clamps are installed.
Torque:
Bolts:
Stage 1:9 Nm
Stage 2:Loosen: 45°
Stage 3:6 Nm
Stage 4:180°
8. Torque: 10 Nm
Procedures).
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
10. NOTE: Only tighten the nuts and bolts finger tight at this stage.
Torque:
1 33 Nm
2 10 Nm
11. Torque: 10 Nm
12. Torque: 10 Nm
13. NOTICE: Extreme cleanliness must be exercised when handling the

components.
NOTE: Only tighten the nuts and bolts finger tight at this stage.
Procedures).
Torque:
1:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°
2 13 Nm
3 10 Nm
14. Torque: 10 Nm
15. Torque:
1 15 Nm
2 48 Nm
3 48 Nm
16. NOTICE: Extreme cleanliness must be exercised when handling the
components.
Torque:
1: 10 Nm
2:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°
17.
18.
Procedures).
20.
21. Torque: 10 Nm
Procedures).
23. Refer to: Timing Belt (303-01A Engine, Removal and Installation).
Engine - 2.0L EcoBlue (77kW/105PS)
(YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN)
- Crankshaft Front Seal
Print
Removal
1. Refer to: Timing Cover (303-01A Engine, Removal and Installation).
Installation

(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Crankshaft Rear Seal
Print

303-1643
Locking Tool, Flywheel
Fluid Container
Plastic Scraper
Materials
Name Specification
Primer -
Silicone Sealant WSE-M4G323-A4
Removal
1. Refer to: Transmission - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)

(YM)/2.0L EcoBlue (125kW/170PS) (YN) (308-03 Manual Transmission, Removal).
Refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and Installation).
2. NOTE: Be prepared to collect escaping fluid.
Use the General Equipment: Fluid Container
3. Install Special Service Tool: 303-1643.

4. Loosen: 2 turn(s)
5. Remove Special Service Tool: 303-1643.

6.

Installation
1.
1. Use the General Equipment: Plastic Scraper
2. NOTE: Make sure that the mating faces are clean and free of foreign
material.
Material: - (Primer)
2.
NOTE: Make sure that the mating faces are clean and free of foreign material.
4. NOTE: The component must be installed within 5 minutes of applying the sealant.
Complete this step within: 5min

Material: WSE-M4G323-A4 (Silicone Sealant)
5. NOTICE: Take extra care not to damage the mating faces.
NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve
which must be removed after installation.
NOTE: Install all the bolts finger tight before final tightening.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
6. NOTICE: Make sure that the flywheel is in full contact with the crankshaft
flange before installing the flywheel bolts.
NOTE: The component can only be installed in 1 position.
Install Special Service Tool: 303-1643.
7. Torque:
Stage 1:15 Nm
Stage 2:30 Nm
Stage 3:75 Nm
Stage 4:45°

9. Refer to: Transmission - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (308-03 Manual Transmission, Removal).
Refer to: Clutch Disc and Pressure Plate (308-01 Clutch, Removal and Installation).
10. NOTE: Use a new seal.
Torque: 39 Nm
11.
12. Refer to: Specifications (303-01A Engine, Specifications).
13.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Cylinder Head—Vehicles Built
From: 01-11-2016
Print

205-069
Dial Indicator Gauge (Metric)
205-070
Holding Fixture, Dial Indicator Gauge
303-1611
Torque Multiplier
303-1611-03
Adapter for 303-1611, Torque Multiplier
303-432
Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion)
1/2 Inch Square Drive Breaker Bar

Fluid Container
Hose Clamp Remover/Installer
Plastic Scraper
Wooden Block
Materials
Name Specification
Brake Cleaner -
Removal
1. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
2. NOTE: Change engine oil and oil filter.
NOTE: Be prepared to collect escaping fluid.
3. NOTE: Make sure a new bolt is installed.
Torque: 39 Nm
5. Refer to: Camshaft and Carrier Assembly (303-01A Engine, Removal and Installation).
6. Refer to: Intake Manifold (303-01A Engine, Removal and Installation).

7. NOTE: Only tighten the bolts finger tight at this stage.

Use the General Equipment: Hose Clamp Remover/Installer
10.
11.

15.
16. NOTE: Make sure that no components catch.
1. NOTE: Note the position of the component before removal.
2.
17. NOTICE: Take extra care when handling the component.

18. NOTE: Note the position of the components before removal.
19. NOTICE: Make sure that the cylinder head is at ambient air temperature
before removing the cylinder head bolts.
Use Power Tool only.
20.

NOTE: Make sure that no components catch.
22. Use the General Equipment: Wooden Block
23.
Installation
1.
material.
2. NOTE: Measure the piston protrusion of each cylinder at top dead center (TDC)
Measure the distance between the piston crown and the cylinder block at the points
indicated.
3. The largest measurement determines the choice of the cylinder head gasket.
Use Special Service Tools: 205-070, 205-069, 303-432.
4. NOTICE: Make sure that no fluids are present in the cylinder head bolt
threaded bores.
1. NOTE: Make sure that a new component is installed.
Refer to: Specifications (303-01A Engine, Specifications).
2. 2. NOTICE: Make sure that the gasket is correctly located.


7. Torque:
Stage 1:15 Nm
Stage 2:25 Nm
Stage 3:40 Nm
Stage 4:90°
Stage 5:90°
8. Mark the position of the bolts.

9. NOTE: Make sure that the component is correctly installed.
Install Special Service Tool: 303-1611-03.
Torque: 10 Nm
10. Install Special Service Tools: 303-1611-03, 303-1611.

Use the General Equipment: 1/2 Inch Square Drive Breaker Bar
Torque:
Stage 6: 90°
11. Remove Special Service Tools: 303-1611, 303-1611-03.

Torque:
Stage 6: 90°
14. Remove Special Service Tool: 303-1611-03.

Torque: 10 Nm

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque: 10 Nm

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque: 10 Nm

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

37. Stage 7: Repeat the steps 9 to 36.
38. 1. NOTE: Component must be lubricated with clean engine oil.
2. NOTE: Make sure that the components are installed to the position noted
before removal.
39. NOTICE: Take extra care when handling the components.

NOTE: Only tighten the nut and bolts finger tight at this stage.
NOTE: Make sure that a new O-ring seal is installed.
1. Torque: 10 Nm
2. Torque: 10 Nm
3. Torque: 20 Nm
4. Torque: 10 Nm
5. Torque: 10 Nm
40. NOTE: Only tighten the nuts and bolt finger tight at this stage.
1. NOTE: Make sure that the component is installed to the position noted before
removal.
Torque: 8 Nm
2. Torque: 25 Nm
41. Torque: 25 Nm
43. NOTICE: The bolts must not be reused more than 1 time.
NOTE: Using a center punch, mark the heads of all bolts which are to be reused.
NOTE: Use a new seal.
44. NOTICE: The bolts must not be reused more than 1 time.
NOTE: Using a center punch, mark the heads of all bolts which are to be reused.
NOTE: Make sure that the seal is correctly located.
Torque:
Stage 1:4 Nm
Stage 2:10 Nm
46. NOTE: Make sure that a new O-ring seal is installed.

Torque: 10 Nm
47.
48. Torque:
1: 25 Nm
2: 25 Nm
3: 10 Nm
49. Use the General Equipment: Hose Clamp Remover/Installer
50. Remove the component.

52. Refer to: Intake Manifold (303-01A Engine, Removal and Installation).
54.
56.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Exhaust Manifold
Print
Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger, Removal
and Installation).
2. Torque: 10 Nm

NOTE: Only tighten the nuts finger tight at this stage.
Torque:
Stage 1:12 Nm
Stage 2:23 Nm
Stage 3:23 Nm
4. Torque: 10 Nm

Torque: 10 Nm
Installation
1. To install, reverse the removal procedure.

NOTE: Make sure that the component is correctly installed.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Intake Manifold
Print
Removal
1. Refer to: Exhaust Gas Recirculation (EGR) Outlet Tube (303-08A Engine Emission
Control, Removal and Installation).
2. Torque: 10 Nm
3.
4. NOTE: Make sure that the seal is correctly located.
Torque:
Stage 1:10 Nm
Stage 2:23 Nm
5. Torque: 8 Nm

Torque:
Stage 1:5 Nm
Stage 2:10 Nm
Installation

(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Oil Cooler
Print

General Equipment
Fluid Container
Removal
1. Refer to: Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
Use the General Equipments: Fluid Container, Hose Clamp Remover/Installer
3. NOTE: Component(s) must be lubricated with clean engine oil.

Torque: 15 Nm
4. NOTE: Be prepared to collect escaping fluids.
NOTE: Install all the bolts finger tight before final tightening.
Torque:
1 55 Nm
2 10 Nm
Installation

2. NOTE: Make sure that the seal is correctly located.
3.

5.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Oil Pan
Print

303-1668
Sealer Gun, Front Cover
303-428
Separator, Oil Pan
Fluid Container
Plastic Scraper
Materials
Name Specification
Primer -
RTV Silicone Sealant WSE-M4G323-A6
Removal
2.
3. NOTE: Change engine oil and oil filter.

5.
Use Special Service Tool: 303-428.
Installation
1.
material.

NOTE: The component must be installed within 10 minutes of applying the sealant.

Material: WSE-M4G323-A6 (RTV Silicone Sealant)
3. Torque:
Stage 1:5 Nm
Stage 2:10 Nm
4. Torque: 39 Nm
5.
7.
9.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Oil Pump
Print
Removal
1. Remove the following items:

• Refer to: Oil Pan (303-01A Engine, Removal and Installation).
2.
3.
4.
5.
Installation
1. NOTE: Make sure that the components are correctly located.

2. NOTE: Only tighten the nuts finger tight at this stage.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
3. Torque: 10 Nm
4.
5. Install the following items:

• Refer to: Oil Pan (303-01A Engine, Removal and Installation).
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Timing Belt
Print

303-1637
Holding Tool, Crankshaft
303-1643
303-1650
Mounting Device, Timing Belt
6 mm Drill Bit
Adhesive Tape
Removal
NOTICE: The crankshaft or camshafts must not be rotated while the timing belt is
removed.

3. NOTE: Only tighten the bolt finger tight at this stage.
4. NOTICE: Only rotate the crankshaft clockwise.

Rotate the crankshaft until piston No. 1 is at top dead center (TDC).
5.
6. NOTICE: The special tool must only be used to align the crankshaft timing.
NOTE: Only tighten the bolt finger tight at this stage.
1. Use the General Equipments: 6 mm Drill Bit, Adhesive Tape
8. Install the General Equipments: 6 mm Drill Bit, Adhesive Tape

9.
Installation
1. NOTE: Make sure that new components are installed.

Torque: 25 Nm

4. Remove the General Equipment: 6 mm Drill Bit

1. Use Special Service Tool: 303-1650.
2. Use the General Equipment: 6 mm Drill Bit


Rotate the crankshaft 4 revolutions.
9.
11. NOTICE: Visually check if the timing holes of the camshaft sprockets are in a
clockwise overlap position to the timing holes in the camshaft module.

(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Valve Springs
Print

Special Tool(s)
303-060
Compressor, Valve Spring
303-060-07
Adapter for 303-060
303-060-09A
Adapter for 303-060
303-362
Installer, Valve Stem Collets
Removal
3. Position the appropriate piston at top dead center (TDC).

4.
Use Special Service Tools: 303-060, 303-060-09A, 303-060-07, 303-362.
5.
Installation

2. NOTE: Component must be lubricated with clean engine oil.
NOTE: Make sure that the components are installed to the position noted before
removal.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Valve Stem Seals
Print

Special Tool(s)
303-508
Pliers, Valve Stem Seal
Removal
1. Refer to: Valve Springs (303-01A Engine, Removal and Installation).
Installation

(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Primary Drive Idler Gear
Print

303-1635
Remover/Installer, Fuel Injection Pump
303-1643
303-1650
4 mm Drill Bit
6 mm Drill Bit
Adhesive Tape
Materials
Name Specification
Clutch and Brake Cleaner -
Removal



7.
8. 1.
3.
9. Max Length 32mm.
Install the General Equipment: 4 mm Drill Bit

11. NOTE: Discard the bolt.
Installation
1. NOTICE:
Make sure that the surface is clean and free of foreign material.
Use lint free cloth.

Material: - (Clutch and Brake Cleaner)
2.

NOTE: Make sure that the installation marks are aligned.
NOTE: Make sure a new bolt is installed.
NOTE: Install the bolt finger tight before final tightening.
Torque:
Standard bolts torque
Stage 1:60 Nm
Stage 3:20 Nm
Stage 4:45 Nm
Stage 5:45°
Self-locking bolts torque
Stage 1:60 Nm
Stage 3:20 Nm
Stage 4:30 Nm
Stage 5:60°


Remove the General Equipment: 6 mm Drill Bit

Torque: 2.25 turn(s)
12.
14.
15. Run the High Pressure Fuel System Reset in FDRS.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine
Print
Removal
303-1196
Holding Wrench, Pulley
307-569
Disconnect Tool TOC Line (1/2)
3.5 mm Drill Bit

Center Punch
Floor Crane
Lifting Bracket
Mounting Table Set
Retaining Strap
Wooden Block
1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables,
3.
4. Refer to: Diesel Particulate Filter (DPF) (309-00A Exhaust System, Removal and
Installation).
5.
6.
7.
8.

11. NOTICE: Make sure that all openings are sealed with clean blanking caps.
Procedures).
12. On both sides.
Refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
14. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).
15.
16.
17.
18.
19. NOTICE: Make sure that the components are not forcibly bent.
If equipped.
21.
22.
23.
24.
25.
26.
27.
28. If equipped.
Use the General Equipments: Center Punch, 3.5 mm Drill Bit
29.
30.
31.
32. NOTICE: Make sure that all openings are sealed with clean blanking caps.
Procedures).
Vehicles With: Rear Climate Control
33. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00
Climate Control System - General Information, General Procedures).
34.
6-Speed Automatic Transmission - 6F55
35.
36.
37.
38.
39.
40.
41. 1.
Use Suggested Tool: 307-569. Tool shown or a commercially available equivalent
can be used.

42. 1.
Use Suggested Tool: 307-569. Tool shown or a commercially available equivalent
can be used.
43.
44. Refer to: Front Halfshaft LH - Detach from the transmission - 6-Speed Automatic
Transmission - 6F55 (205-04 Front Drive Halfshafts, Removal and Installation).
• Refer to: Front Halfshaft RH - 6-Speed Automatic Transmission - 6F55 (205-04
Front Drive Halfshafts, Removal and Installation).
46. NOTE: Note the different lengths of the bolts.
All vehicles
47. WARNING: Always secure engines, transmissions, or other heavy components

to the support fixture with straps and wooden support blocks. Improperly secured
assemblies could fall off the fixture, resulting in serious personal injury.
Install the General Equipments: Mounting Table Set, Wooden Block, Retaining Strap
48.
49.

51. NOTICE: It is mandatory to use the specified materials!
Torque: 33 Nm
52. Install the General Equipments: Lifting Bracket, Floor Crane

53. Remove the General Equipments: Retaining Strap, Wooden Block, Mounting Table Set
54.
55.

NOTE: Note the position of the component before removal.
57.
58. NOTICE: Make sure that the torque converter remains in the transmission.
59. NOTICE: Make sure that the locating dowels remain installed.
Tool shown or a commercially available equivalent can be used.
Install Suggested Tool: 303-1196. Tool shown or a commercially available equivalent

can be used.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine Accessories
Print
Removal
303-1635
303-1643
303-435
Mounting Stand
303-435-04
Mounting Bracket for 303-435
303-435-12C
Mounting Plate
Floor Crane
Lifting Bracket
1.
2.
3.
4. Install Special Service Tools: 303-435, 303-435-04, 303-435-12C.
5. Remove the General Equipments: Floor Crane, Lifting Bracket


8.
9.
10.
11.
13.
14.
15.
17.
19.
20.
21.
22. Torque: 10 Nm
23.
24.
25.
26.
27.
28.
29. NOTICE:
Make sure that the area around the component is clean and free of foreign
material.
Make sure that all openings are sealed with new blanking caps.
30.
31.
32.
33.
35.

Torque: 3 turn(s)
39.
40. NOTICE:
Extreme cleanliness must be exercised when handling the component.
Only use moderate force.

43.
44. NOTE: Discard the bolts.
Discard the clamps.
45.
46.

49.
50.
Print
Disassembly
204-158-01
Adapter for 204-158 (Thrust Pad)
303-1635
303-1637
303-1643
303-428
Separator, Oil Pan
4 mm Drill Bit
6 mm Drill Bit
Adhesive Tape
Fluid Container
Two Leg Puller

2.
3. Use Special Service Tool: 204-158-01.

Use the General Equipment: Two Leg Puller
4.
5. Loosen: 180°

8.

11.
12.
13.


20.
21.
22. NOTE: Make sure that the component is at ambient air temperature.
Loosen each bolt 2 turns at a time until all bolts are removed.
23.
25. NOTICE: Make sure that the cylinder head is at ambient air temperature
before removing the cylinder head bolts.
Use Power Tool only.
26.

28.

31.
1. 1. NOTICE: Make sure that the crankshaft is not rotated
Mark the position of the component.
2. 2. NOTICE: Only rotate the crankshaft clockwise.

3. NOTE: Make sure that the installation marks are aligned.
33. NOTICE: Make sure that the crankshaft is not rotated

2.
3.
34.
36.
37.
38.

40.
41.
42.
43.
44.
45.
46.
47.
48.

NOTE: Discard the bolts.
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Cylinder Head
Print
Disassembly and Assembly of Subassemblies

303-060
Compressor, Valve Spring
303-060-07
Adapter for 303-060
303-060-09A
Adapter for 303-060
303-362
Installer, Valve Stem Collets
303-508
Pliers, Valve Stem Seal
Wooden Block
Disassembly
NOTICE: Take extra care when handling the components.

1. Use the General Equipment: Wooden Block
Torque:
1: 33 Nm
2: 10 Nm
3: 11 Nm
4: 13 Nm
3. Torque: 10 Nm
Torque:
Stage 1:12 Nm
Stage 2:23 Nm
Stage 3:23 Nm

Torque: 10 Nm
6.
Use Special Service Tools: 303-060, 303-060-09A, 303-060-07, 303-362.
7.
8.
9.

Assembly
12. To assemble, reverse the disassembly procedure.

Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS) (YM)/2.0L
EcoBlue (125kW/170PS) (YN) - Engine
Print
Assembly
205-069
Dial Indicator Gauge (Metric)
205-070
Holding Fixture, Dial Indicator Gauge
303-1611
Torque Multiplier
303-1611-03
Adapter for 303-1611, Torque Multiplier
303-1637
303-1643
303-1650
303-1668
Sealer Gun, Front Cover
303-432
Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion)
1/2 Inch Square Drive Breaker Bar

4 mm Drill Bit
6 mm Drill Bit
Plastic Scraper
Materials
Name Specification
Primer -
Brake Cleaner -
RTV Silicone Sealant WSE-M4G323-A6
NOTICE: Extreme cleanliness must be exercised when handling the components.

1. NOTE: Make sure that new bolts are installed.
NOTE: Make sure that the components are correctly located.
Torque: 10 Nm
2. Material: - (Primer)
3. NOTE: Make sure that the component is clean, free of foreign material and lubricant.

4.
Make sure that a new bolt is installed on position 8.
6. Make sure that a new bolt is installed on position 8.
Torque:
1-13 5 Nm
7. Make sure that a new bolt is installed on position 8.
Torque:
1-7: 23 Nm
8: 13 Nm
9-10: 23 Nm
11: 13 Nm
12-13: 23 Nm
8. NOTICE: Make sure that no excess sealant residue is evident.

9. Rotate the crankshaft until piston No. 1 is at top dead center (TDC).
10.
12. NOTICE:
Make sure that the surface is clean and free of foreign material.

13.
1. 1. NOTICE: Make sure that the component aligns with the installation mark.
2. 2. NOTICE: Make sure that a new bolt is installed.

Torque:
Standard bolts torque
Stage 1:60 Nm
Stage 3:20 Nm
Stage 4:45 Nm
Stage 5:45°
Self-locking bolts torque
Stage 1:60 Nm
Stage 3:20 Nm
Stage 4:30 Nm
Stage 5:60°

15.
1. 1. NOTICE: Make sure that the crankshaft is not rotated
Mark the position of the component.
3. 3. NOTICE: Only rotate the crankshaft clockwise.

16. NOTICE:

NOTE: Make sure that the threaded holes are clean and free of foreign matter.
NOTE: The component must be installed by hand before final tightening.

Torque: 23 Nm
18. Install the General Equipment: 4 mm Drill Bit
NOTE: Make sure that the installation marks are aligned.

22.
23.
24. NOTE: Install all the bolts finger tight before final tightening.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
25. Torque: 10 Nm
26. Torque:
1: 10 Nm
2: 10 Nm
27. Torque: 10 Nm
28.
29.

32. NOTICE: Take extra care not to damage the mating faces.
NOTE: New crankshaft rear seal carriers are supplied with an alignment sleeve which
must be removed after installation.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm

34.
35.
36. NOTE: Measure the piston protrusion of each cylinder at top dead center (TDC)
Measure the distance between the piston crown and the cylinder block at the points
indicated.
37. The largest measurement determines the choice of the cylinder head gasket.
Use Special Service Tools: 205-070, 205-069, 303-432.

38. NOTICE: Make sure that no fluids are present in the cylinder head bolt threaded
bores.
2. 2. NOTICE: Make sure that the gasket is correctly located.
dowels.
42. Torque:
Stage 1:15 Nm
Stage 2:25 Nm
Stage 3:40 Nm
Stage 4:90°
Stage 5:90°
43. Mark the position of the bolts.

Torque: 10 Nm

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque: 10 Nm

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque: 10 Nm

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

Torque: 10 Nm

Torque:
Stage 6: 90°

Torque:
Stage 6: 90°

72. Stage 7: Repeat the steps 45 to 72.
73. • NOTE: Component must be lubricated with clean engine oil.
Refer to: Specifications (303-01 Engine - 2.0L EcoBlue (88kW/120PS) (YN), 2.0L
EcoBlue (110kW/150PS) (YM), 2.0L EcoBlue (140kW/190PS) (BC), Specifications).
• NOTE: Make sure that the components are installed to the position noted before
removal.
dowels.
dowels.
NOTE: Make sure that the component is at ambient air temperature.
1. Tighten each bolt 2 turns at a time.
Torque:
1-19 5 Nm
2. Torque:
1-18 10 Nm
3. Torque:
19 23 Nm
77. NOTE: Install all the bolts finger tight before final tightening.
Torque:
1: 10 Nm
2: 10 Nm
3: 20 Nm
4: 13 Nm
5: 11 Nm
6: 10 Nm

Torque: 25 Nm

81.


Rotate the crankshaft 14 revolutions.
86.
88. NOTICE: Visually check if the timing holes of the camshaft sprockets are in a
clockwise overlap position to the timing holes in the camshaft module.
90. NOTICE: Make sure that the flywheel is in full contact with the crankshaft flange
before installing the flywheel bolts.
91. Torque:
Stage 1:15 Nm
Stage 2:30 Nm
Stage 3:50 Nm
Stage 4:90°
Torque:
Stage 1:25 Nm
Stage 2:75 Nm
93.

dowels.
removal.
98. Torque:
Stage 1:12 Nm
Stage 2:80 Nm
Stage 3:90°
100. Torque:
1-2 18 Nm
3-17 10 Nm
101. NOTE: Install the bolt finger tight before final tightening.
NOTE: Make sure a new bolt is installed.
Torque: 55 Nm
102.
Torque:
Stage 1:10 Nm
Stage 3:20 Nm
Stage 4:70 Nm
Stage 5:150 Nm
Stage 7:100 Nm
Stage 8:300 Nm
Stage 9:90°

105.

107. Torque:
Stage 1:5 Nm
Stage 2:10 Nm

Torque: 39 Nm
Print
Installation
303-1196
Holding Wrench, Pulley
Floor Crane
Ford Diagnostic Equipment
Lifting Bracket
Mounting Table Set
Retaining Strap
Wooden Block
Materials
Name Specification
Grease - High Temperature WSS-M1C273-A
Apply a thin coating.
Remove Suggested Tool: 303-1196.

Material: WSS-M1C273-A (Grease - High Temperature)
2. NOTICE: Make sure that the locating dowels remain installed.

3. NOTICE:
Make sure that no part of the wiring harness is trapped.
Make sure that the component is correctly located on the locating dowels.
Only rotate the crankshaft clockwise.

NOTE: Make sure that the component is installed to the position noted before
removal.
4. Torque: 48 Nm
5. Torque: 48 Nm

Torque: 48 Nm
7.
All vehicles
8. Torque:
2: 12 Nm
3: 8 Nm
4: 35 Nm
9. Install the General Equipments: Mounting Table Set, Wooden Block, Retaining Strap
10. Remove the General Equipments: Floor Crane, Lifting Bracket

11.

13. Torque:
1: 115 Nm
2: 70 Nm
14. Torque:
1: 70 Nm
2: 133 Nm
3: 70 Nm
15. WARNING: Always secure engines, transmissions, or other heavy components
to the support fixture with straps and wooden support blocks. Improperly secured
assemblies could fall off the fixture, resulting in serious personal injury.
Remove the General Equipments: Retaining Strap, Wooden Block, Mounting Table Set
16. Torque: 175 Nm

• Refer to: Front Halfshaft RH - 6-Speed Automatic Transmission - 6F55 (205-04
Front Drive Halfshafts, Removal and Installation).
18. Refer to: Front Halfshaft LH - Attach to the transmission - 6-Speed Automatic
Transmission - 6F55 (205-04 Front Drive Halfshafts, Removal and Installation).
19. Torque: 11 Nm
21.
22. Torque: 8 Nm
23. NOTE: Make sure that the component terminals are not bent or damaged.
24.
25. If equipped.
26.
Vehicles With: Rear Climate Control
27.
1. Torque: 20 Nm
2. Torque: 15 Nm
3. Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-
00 Climate Control System - General Information, General Procedures).
All vehicles
Procedures).
29.
30. Torque:
1: 10 Nm
2: 5 Nm
31.
32. Tighten the shear bolt until the head is sheared off.
33.
34.
35.
36.
37. Torque: 10 Nm
38.
39.
Torque: 23 Nm
If equipped.
Torque: 25 Nm

45.
1. Torque:
1: 10 Nm
2: 10 Nm
3: 10 Nm
2. Torque:
1: 23 Nm
2: 23 Nm
3: 23 Nm
3. Torque:
4: 10 Nm
5: 10 Nm
4: 10 Nm
6: 10 Nm
7: 10 Nm
6: 10 Nm
46.
47. Refer to: Generator - 2.0L EcoBlue (77kW/105PS) (YL)/2.0L EcoBlue (96kW/130PS)
(YM)/2.0L EcoBlue (125kW/170PS) (YN) (414-02 Generator and Regulator, Removal and
Installation).

49. On both sides.
50.
Procedures).
53.
54. Torque:
1: 10 Nm
2: 10 Nm
55. Torque: 10 Nm
56. Torque: 10 Nm
57. Refer to: Diesel Particulate Filter (DPF) (309-00A Exhaust System, Removal and
Installation).
58.
61.
62. NOTICE: Make sure that the engine oil is to specification.

NOTE: Make sure that fluid level is to the MAX mark.
63.
64. Refer to: Fuel System Bleeding (310-00A Fuel System - General Information, General
Procedures).
65. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission, General
Procedures).
66. Reset the High-Pressure Fuel System Learned Values.
Use the General Equipment: Ford Diagnostic Equipment

(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Engine Accessories
Print
Installation
303-1635
303-1643
303-435
Mounting Stand
303-435-04
Mounting Bracket for 303-435
303-435-12C
Mounting Plate
308-204
Aligner, Clutch Disc
Floor Crane
Lifting Bracket
Long Nose Pliers
Materials
Name Specification
Grease WSD-M1C227-A
1. Torque: 40 Nm
2.
3. NOTICE: The cone on the special tool must only be tightened finger tight to
prevent damage to the clutch disc.
removal.

Torque: 30 Nm
7. NOTICE: To avoid corrosion, lubricate the injector bodies prior to installation.

NOTE: This step is only necessary if the original component is to be reused.
Use the General Equipment: Long Nose Pliers
9. NOTE: The O-ring seal is to be reused unless damaged.

removal.
Make sure that new clamps are installed.
Torque:
Stage 1:9 Nm
Stage 3:6 Nm
Stage 4:180°
11. Torque: 10 Nm
removal.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
13. Torque: 10 Nm
14.
15.
16.

18.
19.
20. NOTICE:

NOTE: The component must be installed by hand before final tightening.
21. NOTE: Only use moderate force.

Torque: 23 Nm

Remove Special Service Tool: 303-1635.
25. Torque:
1:
Stage 1:5 Nm
Stage 2:18 Nm
2:
Stage 1:5 Nm
Stage 2:10 Nm
27. Torque:
Stage 1:25 Nm
Stage 2:75 Nm
29.
31. NOTICE: Make sure that the area around the component is clean and free of
foreign material.
Torque:
1:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°
2: 13 Nm
3: 10 Nm
4:
Stage 1:12 Nm
Stage 2:16 Nm
Stage 3:50°
Torque:
1: 10 Nm
2: 33 Nm
33. NOTICE: Make sure that the gasket is correctly located.

NOTE: Use a new seal.
Torque:
1: 10 Nm
2: 33 Nm

Torque:
Stage 1:12 Nm
Stage 2:23 Nm
Stage 3:23 Nm
1. Torque: 10 Nm
2. Torque: 10 Nm
Torque:
1: 23 Nm
2: 10 Nm
37.
38. Torque: 10 Nm

NOTE: Use new seals.
Torque:
1: 55 Nm
2: 10 Nm

Torque:
Stage 1:4 Nm
Stage 2:10 Nm
42. NOTE: Component must be lubricated with clean engine oil.
Torque: 15 Nm
Torque: 10 Nm
44.

Torque:
1: 10 Nm
2: 10 Nm
46.
47.
48. NOTE: Make sure that the components are correctly located.
Torque:
1: 23 Nm
2: 23 Nm
49.
1. 1. NOTICE: Use lint free cloth.
NOTE: Make sure that the component is clean, free of foreign material and
lubricant.
Torque:
Stage 1:5 Nm
Stage 2:10 Nm
Stage 3:23 Nm
51. Torque: 63 Nm
52.

54.
Torque: 10 Nm
57. Install the General Equipments: Lifting Bracket, Floor Crane

58. Remove Special Service Tools: 303-435-12C, 303-435-04, 303-435.
59. Torque: 23 Nm
60. NOTE: Only tighten the nut and bolts finger tight at this stage.
Torque:
1: 20 Nm
2: 10 Nm
3: 10 Nm
4: 10 Nm
61. Torque: 63 Nm
(YM)/2.0L EcoBlue (125kW/170PS) (YN) - Timing Cover
Print

303-1554
Engine Support Bar
303-1554-07
Adapter for 303-1554, Engine Support Bar
303-1554-08
303-1554-09
303-1643
303-290A-15
Adapter for 303-290A
303-428
Separator, Oil Pan
Oil Suction Equipment

Plastic Scraper
Two Leg Puller
Materials
Name Specification
Primer -
Silicone Sealant WSE-M4G323-A4
Removal
2. Use the General Equipment: Oil Suction Equipment
3. Right Side Only.
5. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).
6. Refer to: Starter Motor (303-06A Starting System, Removal and Installation).

RHD FWD
8.
All vehicles
9. NOTE: The component must be installed by hand before final tightening.
Use Special Service Tool: 303-1554-09.
Torque: 36 Nm
11. NOTE: The component must be installed by hand before final tightening.
12. Use Special Service Tools: 303-1554-08, 303-1554-07.
13. Install Special Service Tool: 303-290A-15.

15.
16.
17.
18.
19.
20.
23.
25. Use the General Equipment: Two Leg Puller

26. Remove the General Equipment: Two Leg Puller
27. NOTE: Discard the bolt.
30.
Installation
1. NOTICE: Protect the engine and the oil pan from contamination by sealer
debris.
3.

5. NOTE: The component must be installed within 5 minutes of applying the sealant.

dowels.

Torque:
Stage 1:12 Nm
Stage 2:80 Nm
Stage 3:90°

10. Torque:
1-2 18 Nm
3-17 10 Nm
Torque: 40 Nm
12.
13. Torque: 48 Nm
Torque:
Stage 1:10 Nm
Stage 3:20 Nm
Stage 4:70 Nm
Stage 5:150 Nm
Stage 7:100 Nm
Stage 8:300 Nm
Stage 9:90°
16. Torque: 23 Nm
19.
20. Torque: 10 Nm
21.
Torque:
1 115 Nm
2 70 Nm
24. Remove Special Service Tool: 303-290A-15.

25. Remove Special Service Tools: 303-1554-08, 303-1554-07.


RHD FWD
29. Torque: 7 Nm
All vehicles

31. Refer to: Starter Motor (303-06A Starting System, Removal and Installation).
32. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).
33. Right side only.
36.
38.

Ford 2.0 EcoBlue Engine

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Ford 2.0 EcoBlue Engine

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Engine - 2.0L EcoBlue (77kW/105PS) (YL)/2.

NOTICE: These Parts urgently needed by engine removal and installation !

Lifting eye engine 1 GK2Q-17A084-AA

ENGINE DATA - 105 PS

Emission level Stage 6

Firing order 1-3-4-2

Bore diameter 84.01 mm

Compression ratio 16.5:1

Power output at 3500 rpm 77 kW (105 PS)

Torque between 1375 to 2000 rpm 360 Nm

Idle speed 850 rpm

ENGINE DATA — 130 PS

Emission level Stage 6

Firing order 1-3-4-2

Bore diameter 84.01 mm

Compression ratio 16.5:1

Power output at 3500 rpm 95 kW (130 PS)

Torque between 1500 to 2000 rpm 385 Nm

Idle speed 850 rpm

ENGINE DATA — 170 PS

Emission level Stage 6

Firing order 1-3-4-2

Bore diameter 84.01 mm

Compression ratio 16.5:1

Power output at 3500 rpm 125 kW (170 PS)

Torque between 1750 to 2500 rpm 405 Nm

Idle speed 850 rpm

ENGINE DATA — 105 PS

Emission level Stage 6

Firing order 1-3-4-2

Bore diameter 84.01 mm

Compression ratio 16.5:1

Power output at 3500 rpm 77 kW (105 PS)

Torque between 1500 to 2000 rpm 360 Nm

Idle speed 850 rpm

ENGINE DATA — 130 PS

Emission level Stage 6

Firing order 1-3-4-2

Bore diameter 84.01 mm

Compression ratio 16.5:1

Power output at 3500 rpm 95 kW (130 PS)

Torque between 1500 to 2000 rpm 385 Nm

Idle speed 850 rpm

ENGINE DATA — 170 PS

Emission level Stage 6

Firing order 1-3-4-2

Bore diameter 84.01 mm

Compression ratio 16.5:1

Power output at 3500 rpm 125 kW (170 PS)

Torque between 1750 to 2500 rpm 405 Nm

Idle speed 850 rpm

ENGINE OIL CAPACITY WITH GREY DIPSTICK END

Initial fill including oil filter 9.1

Oil Service fill without filter change 8.1

Oil service fill with filter change 8.3

ENGINE OIL CAPACITY WITH YELLOW DIPSTICK END

Initial fill including oil filter 10

Oil Service fill without filter change 9.2

Oil service fill with filter change 9.8

CYLINDER BLOCK DIMENSIONS

Cylinder bore diameter 84.000 - 84.020

Main bearing housing diameter 65.000 - 65.020

Main bearing running clearance 0.035 - 0.065

Piston diameter 83.915 - 83.931